Automatic cushion stuffer with belt conveyer and reciprocating follower



y 1952 E J. STAUFFER 2,597,397

AUTOMATIC CUSHIN STUFFER WITH BELT CONVEYER AND RECIPROCATING FOLLOWER Filed Nov. 29, 1946 5 Sheets-Sheet 1 INVENTOR EDWARD J. STAUF FER BY WM 7 ATTORNEYS May 20, 195 E. J. STAUFFER 2,597,397

AUTOMATIC CUSHION STUFF'ER WITH BELT CONVEYER AND RECIPROCATING FOL-LOWER Filed Nov. 29, 1946 5 Sheets-Sheet 2 INVENTOR DJ. ST

IQUFFER EDWAR ATTORNEYS May 20, 1952 E. J. STAUFFER AUTOMATIC CUSHION STUFF'ER WITH BELT CONVEYER AND RECIPROCATING FOLLOWER Filed Nov. 29, 1946 FIG. 3

5 Sheets-Sheet 5 EL r wk .ll" j" H [0 E qn 5 w m r l NVENTOR D J. STAUFFE ATTORNEYS May 20, 1952 E, J, STAUFFER 2,597,397

AUTOMATIC CUSHION STUFFER WITH BELT CONVEYER AND RECIPROCATING FOLLOWER Filed Nov. 29, 1946 5 Sheets-Sheet 4 INVENTOR EDWARD J. STAUFFER ATTORNEYS May 20,1952 EDJ. STAUFFER 2,597,397

AUTOMATIC CUSHION STUFFER WITH BELT CONVEYER AND RECIPROCATING FOLLOWER 5 Sheets-Sheet 5 Filed Nov. 29, 1946 INVENTOR EDWARD J. STAUFFER a; W la 65/ 58 AATTORNEYS atented May 20, 1952 AUTOMATIC CUSHION STUFFER WITH BELT CONVEYER AND RECIPROCAT- ING FOLLOWER Edward J. Stauffer, Naperville, Ill., assignor to Kroehler Mfg. 00., Naperville, 111., a corporation of Illinois Application November 29, 1946, Serial No. 712,859

. The present invention relates to apparatus for manufacturing upholstery cushions or the like and is concerned more particularly with a stuffing machine in which the cushion filler charge is advanced on a conveyor belt from a loading position until ultimately it is discharged into a cushion covering material preparatory to sealin and completion.

In its specific contemplation as herein disclosed the present invention is applied to a cushion stuifing apparatus in which the cushion filler is made up of a spring assembly enveloped with fibrous padding. The cushion covering is made of a substantial ornate and serviceable fabric of which all of the defining panels but one are previously positioned and sewn together. The stufiingcharge is advanced on a conveyor system until it arrives in a position in transverse alignment with the distended cushion covering. Thereafter, electrically supervised timing apparatus functions to operate a compression .mechanism which thereupon constricts the filler charge so that it may be inserted into the liner or covering material, the latter member being held on the outermost end of a metallic chute or sleeve.

The filler charge after being compressed passes through the chute and is positioned within the liner by av transversely operating plunger. Further movement of the plunger discharges the filler load and cushion liner together, after which the cushion is completed by sewing into place the remaining open panel.

For a more comprehensive understanding of the present invention, reference will now be had to the accompanying drawings and to the following detailed specification and in which like reference characters designate corresponding parts throughout and in which:

Fig. 1 is a plan view of a cushion stufiing apparatus and filler charge conveyor with a portion of the discharge chute broken away;

Fig. 2 is a front elevation of the apparatus featuredin Fig. 1.

Fig. 3 is an end elevation of the same apparatus viewed as indicated by the line 3--3 in Fig. 1.

Fig. 4 is an enlarged rear elevation of the com-. pression framework and the related end of the conveyor apparatus. 7

. Fig. 5 is an enlarged detail view of a reversing switch mechanism for controlling the direction of rotation of the press operating motor.

Fig. 6 is a transverse sectional view through the 'plungeroperating mechanism and its gear reversing train.

4 Claims. (Cl. 226-45) Fig. 7 is a perspective view of a portion of the conveyor belt showing an adjustable wall bracket mounted thereon; and t Fig. 8 is a sectional detail View of a safety catch lever and is taken approximately on line 8-8 of Fig. 4 showing the lever in full as well as in dotted positions. I

Referring now more particularly to the illustrations in the accompanying drawings, attention is directed in Figs. 1 and 2 to the endless conveyor belt generally designated H with its articulated link elements comprising two spaced chain components which are adapted to mesh with the idler sprockets l2 at one end of the conveyor system and with the driving sprockets l3 at the other end. The driving sprockets l3 rotate clockwise as viewed in Fig. 2. being powered.

is driven by a motor 22 which rests in the base structure 23, Figs. 2 and 4, and in addition to driving the gear train l9, motor 22 also drives through a gear reduction system carried in the unit 23, a cycling or timing platform 24 which carries one or more impulsing cam projections 25 for a purpose which will be further described hereinafter.

Attention is again directed to the link belt l5 which drives the conveyor shaft l4, Fig. 1. It is to be noted that alongside the driven gear I6 is a clutch hub 26 in which are provided conventional elements of a driving coupling supervised or controlled by means of a bell crank 28 pivoted at 29 and periodically actuated as will later be explained for the purpose of advancing the conveyor belt from one position of alignment to another intermittently, a condition of alignment being such as that illustrated in Fig. 4, whereat a filler charge disposed between the confining walls 3! and 32 is positioned beneath the compression head 33, carried by the screw 'actuated plunger 34.

At the end of the conveyor featured in Fig. 1 there is provided a supporting tower structure? generally designated 35 made of vertical angle members 36, a top cross member 31, motor supporting platform 23' andrthe intermediate reenforcingstraps 38. The compression head 33 is carried at the end of a plunger casting 4| reenforced by the truss straps 42 on the lower extremity of the plunger shaft 34, the upper end of which is screw threaded as best seen in Figs. 2, 3 and 4. The lower portion of the shaft 34 is splined as at 43 and by means of a key carried in the supporting structure at 44 the shaft 34 is conf ned against rotation being instead limited to vertical motion when the threaded driving nut 45, Fig. 4,

is actuated by the reversible driving motor 45 Shaft 34 after passing through the threadeddriving nut 45 is guided as at 41 so as to align the compression head 33 with the space between the two confining walls 3I and 32. The depth of stroke, which is described by the compression head 33, is regulated by means of a pair of limit switches 48 and 49 which are adjustably mounted upon the structural elements 5I. Each switch is 1 the conveyor system thereat is represented by a pair of endless link belts designated 53 and 59. These belts are held in alignment because their respective driving and idler sprockets I3 and I2, there being two on each shaft, are integrated for this purpose. The conveyor is provided with a series of cross bars SI as best shown in Figs. 1, 2 and 7, each secured to a related pair of opposed links on the belts 58 and 53 and each provided at one end with la ching plates 52 extend ng above the surface of the bars GI and having the :1

latch receiving openings 63. At the opposite end each cross bar BI is correspondingly provided with a narrow end plate 64, similarly provided with openings 65. Into one or the other of the openings 65 of each plate 64 there may be insertcd the bayonet projection 66 of an immovable rod welded to the sheet metal floor piece 61, which comprises one or the other of the wall members 3| or 32. The upright panel 68 of said wall member merges into an angling flange 69, and the assembly is held rigid having welded between the flange 69 and the floor piece 61,.

a pair of endwardly disposed brace rods 1 I.

In opposition to and in linear alignment with each rigid bayonet rod 66, there is provided a slidably latching rod 12 which resembles a conventional barrel bolt and which may be manipulated by the handle I3. After the rod 66 has been inserted into an opening 65 of a plate 64 and the rod I2 is inserted into an opening 63 of an opposite plate 52, an end wall element 3i or 32 is thereby effectively anchored to the conveyor system so as to swing freely around the end sprockets, as best indicated in Fig. 2 and in all respects to move as a portion of the conveyor system, generally designated I I.

At the end of the apparatus remote from the.

35, a loading operator fills the superstructure 3 I and space between the conveyor wall elements 32 with the cushioning material or batting which may include an integrated upholstery spring assembly covered by suitable fibrou packing or batting and the charges thus placed advance by intermittent steps rightwardly, as viewed in Figs. 1 and 2 (leftwardly as viewed in Fig. 4) until each charge reaches the compression position or station which for convenience will also be designated as the alignment position, beneath the compression head 33.

Just before this position is attained by each 4 successive charge, an engaging pin 8| carried at one end of each of the wall members 32, see Figs. 4 and '7, encounters a pivoted hook 82 articulated at 83 to a bar 84, rotating the latter member throughout a small angle counterclockwise about its pivot 85. As a result of this operation, the bar 86, which is pivoted at 81, is thrust leftwardly, Fig. 4, distending the return spring 88 which is connected'between an integral projection 89 of bar 86 and the guide bracket 9I, causing the adjustable actuating screw 92, Fig. 1,

, to engage the bell crank 28 and rock the latter clockwise about its pivot 29. This effects a declutching operation, whereby the driving connection between the chain I5 and the conveyor II is momentarily broken.

As a further result of the aforedescribed counterclockwise movement on the part of control lever 84, a camming pin 93 carried thereby and riding within the slot 94 of a bell crank lever 95, Fig. 4, causes said bell crank lever to be rotated counterclockwise about its pivot 96 so that the opposite end of said bell crank lever 95, carrying a pin 97, which at this time engages beneath the shoulder 98, raises the slidable control rod or bar 99 from its position as indicated in Fig. 4 to one sufficiently higher therefrom to effect a reversal of the relative disposition of the switch arms IDI and I02, Fig. 5, of the reversing switches I03 and I04. As a consequence electric current introduced to the winding of motor 43 is in such direction as to cause the driving nut 45 to lower the threaded plunger shaft 34, which opera ion will continue until the shoulder I05 encounters the limit switch lever 53, at which time the current will be arrested momentarily while the discharging operation takes place.

Carried on the plunger 33 is a camming finger 39, Figs. 4 and 8, which as the head reaches its lowermost extremity of travel, engages the tail end 90 of a safety lever pivotally supported on an inert part of the machine, and having a blocking finger I90 that is placed into the path of rocker bar 84 so as to prevent the latter from rotating clockwise about its pivot 85 sufficiently to cause the inadvertent reengagement of the driving clutch 21. This safeguard is provided in order to assure that the conveyor apparatus is not reinstated into motion while the compression head 33 is in its down position, but instead to delay the restarting of the conveyor until after the head 33 has cleared the level of the confining walls 3I and 32.

When the cushion compressing head 33 reaches, its lowermost limit of travel as may be adjustably predetermined by placement of the limit switches, the projection I01, Fig. 3, which is carried on the extremity of the beam I08 strikes the head I09 of a bar III, see also Fig. 6, which is supported on the guide brackets II2 and depresses said bar III against the. tendency of return spring II3 until a pin II 4 carried by said bar strikes the inclined surface of a cam pr o jection I I5 integral with an arm I I6. I 7 As a result of the previously described engagement, cam I I5 is moved leftwardly as viewed in Fig. 6, carrying with it the arm IIG which is articulated at II! to a shifting lever II8, where-- upon the latter rotates clockwise about itsstationary pivot II9 causing its idler pinion I33 to come into meshing engagement with the rack' bar I22.

Attention will now be momentarily directed to a driving motor I23 which is continually oper-' ated and whose driving pinion I24 meshes with the links of a chain belt I25, imparting counterclockwise rotation to the driven gear I26. A.

driving gear I21 which is fast to the shaft I28 that also carries the aforesaid driven gear I26 thereupon extends the counterclockwise rotation through its link belt I29 to a driven gear I3I, which is integrally associated with a driving gear Said gears I3I and I32 rotate freely on shaft H9 and gear I32 meshes with a pinion I2I which in turn meshes with a companion pinion I 33. Consequently, pinion I2I undergoes clockwise rotation as viewed in Fig. 6 while pinion I33 rotates continuously in a. counterclockwise direction.

' When, therefore, the rocking lever I I8 is thrust clockwise effecting meshing engagement between pinion I33 and bar I 22, the latter member being part of the thrust ejector I34 moves to the left (see Fig. 3), until the ejector head I35 discharges the compressed cushion package out from be-.

neath the piston head 33 into the rectangular enveloping sleeves I36 and I31, Fig. 2, on the outside of which the operator has previously placed the partially sewn cushion cover. In fact the thrust imparted by the plunger I34 extends far enough so that the cushion package engages the sewn cushion cover causing the latter to be withdrawn from said enveloping sleeves at which time the cushion stufiing operation is completed.

Plunger I34 which is indicated cross-sectionally in Fig. 4 carries an arm IIO which supports a tripping finger I20. During the leftward movement of plunger I34 as viewed in Fig. 6, finger I20 engages the camming surface I30 of a release bar, I40 moving it leftwardly against the influence of its spring I50. However, on the return movement of plunger I34 rightwardly, Fig. 6, this finger engaging the opposite surface of camming projection I30 forces bar I40 rightwardly and to strike the control rod 99 shifting the latter to the right, Fig. 4. As a result, the shoulder 93 is dislodged from the pin 91 and the bar 99 is permitted to descend in response to gravity aided by its return spring I48.

When the stuffing operation is finished the cushion cover is closed by sewing its remaining open flap into position thereby completely encasing the cushion filling. As the plunger I34 and its continuation J22 reach the extremity of travel, a pin I38 on the tail .end of the rack bar I22 engages the control lever I39 which is pivoted at MI and articulated through a link I42 with the lever I I8. As a result the lever I I8 is rocked in a counterclockwise direction about its pivot I I 9, whereupon pinion I33 is withdrawn from engagement with rack I22 and pinion I2I is shifted to so engage in its stead. As a result of the striking of pin I38 against the upper end of lever I39 the latter is rotated counterclockwise and through link I42 lever H8 is also rotated counterclockwise withdrawing driving pinion I33 from engagement with rack bar I22 and since this movement partakes of sufficient momentum the overcentering spring I 43 carries the movement beyond dead center causing the pinion I2I to engage the. teeth of rack bar I22. The clockwise rotation of pinion I2I withdraws the plunger I34 to the condition in which it is illustrated in Fig. 6 at which time another pin I44 carried at the side of rack bar I22 engages the upper extremity of lever I39. In this case, however, the pin I44 is so critically located that its thrust is sufficient only to reinstate the assembly into a neutral position. That is to say, its striking upper surface of the conveyor.

against the lever I39 and rocking it in a clock wise direction is a critically milder thrust so. that the motion transmitted through link I42 to lever I I8 withdraws the pinion I2I from mesh-. ing engagement with rack bar I22, but does not surface a number of cams 25 already mentioned. above. The operation cycle is so regulated that a cam 25 among several such cams that may be. carried by disc 24 encounters the follower wheel I45 at the end of the trip bar I46. The latter member is confined for vertical motion in a pair of brackets I41 and when raised, this member engages the hook lever 82 which is pivoted at 83 lifting it clear of the pin 8I. This frees lever 84 which is under influence to rotate clockwise about its pivot 85 by virtue of the clockwise torque of bell crank communicated to the latter member by the reversing bar 99 whose shoulder 98 has been resting on the bell crank pin 91. This force is not only gravitational, but is supplemented by the spring I48. As a consequence bar 99 drops down sufficiently to reverse the switches I 03 and I04 whereupon the motor 46 begins to operate in a direction for lifting th screw 34.

As a further result of the clockwise motion of lever arm 84 which pulls at its articulation pivot 81 the clutch control bar 86 is moved rightwardly, Fig. 4, reengaging clutch 21 and caus-' ing the rotary motion of continuously rotatinggear wheel I6 to be imparted to the conveyor system. Meanwhile, the attendant at the far end of the conveyor. has placed another cushion ,stuffing assembly into a space between another pair ofbrackets 3I and 32, first appearing on the 7 Between such loading operations this attendant may be occupied in preparing the coil spring assembly by enveloping it with felt padding. When the cam 25 has overridden the roller I45, bar I46 drops back to its lowermost position and the hook lever 82' is freed so as to be engaged by an oncoming pin SI of the next supporting bracket 32.

Thus, there is described a complete cycle of operation on the part of the automatic mechanism. It is to be observed additionally that but two attendants are required to supplement the work performed by the described machine, one of whom supplies the conveyor with cushion loads or charges and the other of whom applies the cushion coverand stands ready to receive the filled cushion and cover at the time the plunger I34 makes its cycle of operation.

In order to replace a succeeding cushion cover upon the overlapping sleeve elements I36 and I31, the latter members are mechanically compressible one within the other under the control of a foot pedal I5I, Fig. 2, which is pivoted at I52 and to which is connected at I53 a spring loaded link I54 at whose upper extremity there are pivotally articulated as at I55 the spreader arms I56 and I51. The effect of depressing pedal I5I is to pull link I54 downwardly to draw the link arms I56 and I 51 inwardly, and thereby to shift the lever arm I58 leftwardly so that its yoked extremity I59 engaging collar l6l moves the latter toward the left and with it the threaded shaft I62. This shaft is screw threaded as at I63 and may thereat be adjusted with respect to a bracket I64 carried by element I36. A spring (not shown) maintains the sleeve assembly I36-l31 distended until overpowered by the aforedescribed foot pedal mechanism.

This foot control makes it possible to apply a cushion cover easily and more conveniently and without having to pull it over these elements under spring tension.

While the present invention has'been explained and described with reference to a more or less specific embodiment, it is to be understood, nevertheless, that a reasonable realm of modification and variation may be incorporated without departing from the essential spirit or scope thereof.

The invention claimed is:

1. In a cushion stuffing machine, a conveyor mechanism for advancing a plurality of cushion stufiing charges from a charging station to a compressing station intermittently, a compressing apparatus at said compressing station for constricting cushion stuiiing charges carried by said conveyor mechanism, an expansive sleeve for holding a cushion covering material in alignment with the compressing apparatus, a plunger for discharging the compressed material into said cushion covering including a cyclically operable power train apparatus, an automatic tripping mechanism having a normally poised position from which it is initiated by said compressing apparatus for releasing said plunger, and a timing cam for reinstating said tripping mechanism to its poised position.

2. In an automatic machine for manufacturing upholstered cushions, a conveyor having a plurality of sets of filler material confining partitions, each adjustable on said conveyor in accordance with predetermined dimensions, a power operated train for actuating said conveyor throughout intermittent steps of advancement corresponding to distances between consecutive sets of said filler partitions, a clutch between said train and said conveyor, means responsive to the arrival of each set of filler partitions before a compression position for declutching the power train from the said conveyor, a pair of reversing switches, said means including a control lever movable to also supervise said pair of reversing switches, a compression head including an electric motor capableof reversible rotation under the supervision of said pair of reversing switches,

electric circuit connections between an energlz ing source and said reversible motor under the supervision of said switches for moving said compression head downwardly to a predetermined adjustable level, a cushion discharging plunger,

a power driven train for thrusting said plunger outwardly and for retracting said plunger, and means controlled by said plunger for reinstating said reversing switches and for reclutching said conveyor and said conveyor driving train.

3. In an automatic cushion stuffing apparatus, a power source, a conveyor apparatus for advancing filler loads to a compression station, a clutch for connecting said power to said conveyor apparatus, a motor driven compression mechanism at said compression station for compacting said filler loads, a discharging plunger for ejecting said filler loads, and automatic means responsive to each attainment by said conveyor of said compression station for declutching said power source from said conveyor, for initiating the compression plunger, and for operating said plunger.

4. In an automatic machine for filling furniture cushions comprising a conveyor having a plurality of confining partitions, a power operated train for advancing said conveyor intermittently, means responsive to each intermittent advancement of said conveyor for declutching said train from said conveyor, a pair of motor reversing switch devices, a compression head including an electric operating motor wound for reversible rotation under the alternative supervision of said pair of switch devices, electric circuit comiections between an energizing source and said motor under the supervision of said switch devices for moving said compression head downwardly and upwardly in separate operations, a cushion discharging plunger including a power driven train for projecting and retracting said plunger, and means controlled by said plunger for operating said reversing switch devices.

EDWARD J. STAUFFER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 716,354 Wagner Dec. 16, 1902 917,221 White Apr. 6, 1909 1,570,432 Busse Jan. 19, 1926 2,048,156 Gardner et al July 21, 1936 2,380,624 Young July 31, 1945 

